Methods for manufacturing barrier systems having a retained coupling pin

ABSTRACT

A method of manufacturing a barrier assembly includes: forming a barrier inside a mold using a polymeric material; removing the formed barrier from the mold while the barrier is still warm; inserting an elongated coupler into a passage on the barrier while the barrier is still warm, the coupler including a shaft and a securing member outwardly projecting from the shaft, the passage having a constricting portion, the warm constricting portion of the barrier pliably bending as the securing member passes throughthrough; and allowing the formed barrier to cool and harden, the hardened constricting portion of the barrier preventing or limiting the securing member of the connector from passing back through the constricting portion of the passage.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No.12/646,572, filed Dec. 23, 2009, now U.S. Pat. No. 8,167,512, which isincorporated herein by specific reference in its entirety.

BACKGROUND OF THE INVENTION

1. The Field of the Invention

The present invention relates to barriers, and more particularly,methods for manufacturing portable, reusable, control barrier systemsthat have a retained coupling pin.

2. The Relevant Technology

Control barriers are used in a variety of situations. For example,control barriers can be selectively positioned at special events orconstruction sites to help direct pedestrian and automobile traffic in adesired direction. Similarly, control barriers can be used at airportsto delineate construction zones and direct ground traffic and taxiingaircraft in a desired direction. Alternatively, control barriers can beput up to help limit access to select areas. In yet other embodiments,control barriers can be put up to define an entertainment stage or theboundaries of a playing field. For example, control barriers can be usedto define the boundaries of a soccer field or an ice skating rink.Control barriers are also being used on runways and taxiways of airportsto help guide airplane traffic.

Conventional control barriers have long comprised individual sawhorsetype barriers or collapsible V-shape barricades. Such barriers, however,have limited use since they are generally lightweight and are thuseasily tipped over or moved. This can be especially problematic whenused at airports in conjunction with aircraft where the barriers cannotwithstand the propeller wash or jet blast produced by aircraft and willbe blown over or blown out of position. Similar problems also occur whensuch conventional barriers are used in other high impact environments.Other airport problems can arise due to the height of the barriers,which can cause damage to engines, wings, or other portions of aircraftthat do not clear the height of the barrier. In addition, thelightweight barrier or any portion thereof can potentially be sucked into the engine of the aircraft, thereby potentially causing a great dealof damage that is typically extremely expensive to repair andpotentially dangerous to the passengers on the aircraft.

Furthermore, conventional barriers are typically not connected togetherand often have spaces or gaps extending therebetween. As such, it ispossible for individuals or ground equipment to either slip between orthrough the barriers.

Other barriers comprise various gates or walls that are mechanicallyassembled. Such barriers, however, require extensive time to assembleand disassemble. In yet other alternative embodiments, concrete barriershave been used. Although concrete barriers are not easily tipped overand can withstand impact, such as the propeller wash or jet blast ofaircraft, such barriers are extremely heavy. As such, they are difficultto move and place in desired locations. Often, special equipment such asforklifts or cranes are required. Furthermore, concrete barriers can beboth difficult and expensive to move over large distances and require alarge area to store. Concrete barriers can also be dangerous in thatthey are rigid and non-forgiving when impacted by a person, car, ortaxiing aircraft.

In one attempt to overcome some of the above problems, plastic barriershave been made. The plastic barriers are hollow and can be filled withwater for stabilizing. Although an improvement, existing plasticbarriers also have several limitations. For example, plastic barriersare typically large and bulky. As a result, they are not easily stackedand require large areas to store and transport. Furthermore,conventional plastic barriers are typically too large to meet the strictrequirements of being placed on the taxiway or runway of an airport. Inaddition, when used on taxiways or runways, portions of the barriers canbreak away or detach, which can also lead to potential damage to theengines, as discussed above.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the present invention will now be discussed withreference to the appended drawings. It is appreciated that thesedrawings depict only typical embodiments of the invention and aretherefore not to be considered limiting of its scope.

FIG. 1 is a top perspective view of one embodiment of a barrier assemblyaccording to the present invention;

FIG. 2 is a bottom perspective view of the barrier assembly shown inFIG. 1;

FIG. 3 is a cross-sectional side view of the projection portions at eachend of the barrier shown in FIG. 1;

FIGS. 4 and 5 are top and bottom views, respectively, of one of theprojection portions of the barrier shown in FIG. 1;

FIGS. 6 and 7 are cross-sectional side and end views, respectively, ofthe ends of a pair of barriers shown in FIG. 1 coupled together by thecoupler shown in FIG. 1;

FIGS. 8-10 are top plan views of a pair of barriers shown in FIG. 1coupled together at various angles of connection;

FIG. 11 is a perspective view of one end of the barrier shown in FIG. 1showing an alternative engaging mechanism;

FIGS. 12A and B are side perspective and top plan views, respectively,of the coupler shown in FIG. 1;

FIG. 13 is a perspective view of the formed barrier and coupler shown inFIG. 1, after being removed from the mold;

FIG. 14 is a front view of an alternative embodiment of a coupleraccording to the present invention;

FIGS. 15A and 15B are front and cross-sectional top views, respectively,of another alternative embodiment of a coupler according to the presentinvention;

FIG. 16 is a cross sectional front view of a portion of an alternativeembodiment of a coupler attached to a barrier;

FIG. 17 is a cross sectional front view of a portion of anotheralternative embodiment of a coupler attached to a barrier;

FIG. 18 is a cross-sectional front view of a pair of barrier assembliesshown in FIG. 1 stacked together for storage or transport;

FIG. 19 is a top perspective view of another alternative embodiment of abarrier according to the present invention;

FIG. 20 is a bottom perspective view of the barrier shown in FIG. 19;

FIG. 21 is a perspective view of a flag assembly that can be used withthe inventive barriers;

FIG. 22 is a partial cross sectional side view of the flag assemblyshown in FIG. 21 mounted on a barrier;

FIG. 23 is an enlarged view of the circled area 23 shown in FIG. 22; and

FIG. 24 is a cross sectional side view of an alternative retainer thatcan be used to retain the flag assembly on a barrier.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As used in the specification and appended claims, directional terms,such as “up,” “down,” “left,” “right,” “upward,” and “downward” are usedherein solely to indicate relative directions in viewing the drawingsand are not intended to limit the scope of the claims in any way.

Depicted in FIGS. 1 and 2 is one embodiment of an inventive barrierassembly 100 incorporating features of the present invention. As shownin FIG. 1, barrier assembly 100 comprises a barrier 102 and a separate,discrete coupler 104 secured thereto.

Barrier 102 has an interior surface 106 and an opposing exterior surface108, the interior surface 108 bounding a chamber 110 that is adapted toreceive a ballast. As used in the specification and appended claims, theterm “ballast” is broadly intended to include any materials which can bepoured into internal chamber 110. By way of example and not bylimitation, the ballast can include water, salt water, non-freezingfluids, sand, rock, cement, concrete, and the like.

Barrier 102 comprises a central body portion 112 having a floor 114 anda longitudinal axis 116 extending between a first end 118 and anopposing second end 120. Central body portion 112 further comprisesopposing side walls 122 and 124 extending between floor 114 and a topwall 126. Floor 114, side walls 122 and 124, and top wall 126 eachextend from a first end face 130 disposed at the first end 118 ofbarrier 102 to a second end face 132 disposed at the second end 120 ofbarrier 102. First end face 130 and second end face 132 can besubstantially flat, curved, or have other configurations. In thedepicted embodiment, first end face 130 and second end face 132 are eachsubstantially planar so as to form a flat surface between opposing sidedwalls 122 and 124.

Top wall 126 can be flat, as depicted in FIG. 1, or can be rounded, orhave other shapes. Side walls 122 and 124 are depicted as slopingdownward and away from top wall 126. That is, side walls 122 and 124 arerelatively closer to each other where side walls 122 and 124 adjoin topwall 126 than where side walls 122 and 124 adjoin floor 114. In otherembodiments, side walls 122 and 124 are relatively parallel to eachother and in still other embodiments, side walls 122 and 124 can berelatively closer to each other where side walls 122 and 124 adjoinfloor 114 than where side walls 122 and 124 adjoin top wall 126.

In one embodiment, a display portion 134 can be formed into one or bothside walls 122 and 124 so that displays or other structures can bemounted on side walls 122 and/or 124. For example, as shown in FIG. 1,display portion 134 is recessed within side wall 122 and issubstantially rectangular. In other embodiments, other shapes can beused. In the embodiment depicted, display portion 134 is sized so thatreflective tape 135, such as a high intensity reflective sheeting, canbe attached thereto. Alternatively, a reflective coating can be paintedon or otherwise attached to display portion 134.

Display portion 134 can be sloped relative to the vertical to, e.g.,reflect light upward toward a car driver or a pilot who may be many feetabove the ground in an aircraft cockpit. The amount of slope of displayportion 134 may or may not coincide with the slope of side wall 122.That is the slope of display portion 134 relative to vertical may be thesame as side wall 122 or may be different. In the embodiment depicted,display portion 134 angles inward from side wall 122 toward oppositeside wall 124 as display portion 134 rises toward top wall 126. Theslope is such that the distance between display portion 134 and oppositeside wall 124 is greatest near floor 114 than near the top of displayportion 134. For example, in the embodiment depicted, display portion134 forms an angle θ of about three degrees relative to vertical. Inalternative embodiments, angle θ can be in a range between about 2degrees to about 15 degrees with about 2 degrees to about 10 degrees orabout 2 degrees to about 5 degrees being more preferred. Other anglescan also be used. It is appreciated that side wall 124 can include adisplay portion 134 in like manner to side wall 122. Thus, in otherembodiments display portions 134 can be disposed in parallel planes, caneach slope in intersecting planes, or one wall can be vertical while theother wall slopes relative thereto.

As shown in FIG. 2, a pair of spaced apart fork lift channels 136 and138 are recessed on floor 114 and extends from side wall 122 to sidewall 124. Fork lift channels 136 and 138 are configured to receive thetines of a fork lift such that, if desired, barrier 102 can be moved bya fork lift even if filled with ballast. If desired, pads comprised ofrubber, old car tires, or other material having a higher coefficient offriction than barrier 102, can be secured to floor 114 to increase thecoefficient of friction of barrier 102.

Returning to FIG. 1, one or more inlet ports 140 are formed on top wall126. Each inlet port 140 extends through barrier 102 so as tocommunicate with chamber 110. Accordingly, barrier 102 can be filledwith ballast by passing the ballast through inlet port 140 and intochamber 110. Each inlet port 140 can be selectively closed or sealed bya cap 142. Inlet ports 140 can each comprise a thread molded into topwall 126 to allow the cap to be screwed onto barrier 102. Alternatively,a threaded insert can be molded, welded, or otherwise attached to topwall 126 to form inlet port 140. Instead of a cap, either of inlet ports140 can be selectively closed by a light assembly so as to eliminate theneed for cap 142. Various examples of inlet ports, caps, and lightassemblies that can be used are disclosed in U.S. patent applicationSer. No. 11/828,925, filed on Jul. 26, 2007, which application isincorporated herein by specific reference. It is appreciated that inletport 140 can be positioned at other locations on barrier 102. Forexample, inlet port 140 can be formed directly on barrier 102 anywhereon top wall 126, or on an upper portion of either of side walls 122 or124.

As shown in FIGS. 1 and 2, barrier 102 further includes a firstprojection portion 150 and a second projection portion 152 respectivelyprojecting longitudinally outward from first end face 130 and second endface 132 of central body portion 112. Projection portions 150 and 152are configured such that for identical barriers 102, the firstprojection portion 150 of one barrier can overlap the second projectionportion 152 of the other barrier while the floor 114 of both barriersare resting on a common support surface, as discussed in further detailbelow.

First projection portion 150 comprises a top surface 154 and an opposingbottom surface 156 with a perimeter sidewall 158 extending therebetween.In the depicted embodiment top surface 156 of first projection portion200 lies in the same plane as top wall 126 of central body portion 112so as to be horizontally displaced when barrier 102 is positioned on alevel surface. Alternatively, top surface 156 can lie in a differentplane than top wall 126. Bottom surface 156 projects longitudinallyoutward from first end face 130 on first end 118 and is substantiallyparallel to top surface 154 and thus also horizontally displaced whenbarrier 102 is positioned on a level surface. Other orientations canalternatively be used.

Perimeter sidewall 158 is substantially vertical as it extends betweentop surface 154 and bottom surface 156, although this is not required.First projection portion 150 is rounded on a distal end such that theend of first projection portion 150 is substantially semi-circular whenviewed from a position perpendicular to bottom surface 156 of firstprojection 150. In the depicted embodiment one end of sidewall 158attaches to central body portion 112 and lies in the same plane as sidewall 122 and the other end of sidewall 158 attaches to central bodyportion 112 and lies in the same plane as side wall 124.

Extending completely through first projection portion 150 between topsurface 154 and bottom surface 156 is a passage 162. Passage 162 isgenerally centrally located on first projection portion 150. Turning toFIG. 3, passage 162 is formed by an internal sidewall 164 having anoutside face 166 and an opposing inside face 168. The outside and insidefaces 166 and 168 extend from a top mouth 170 at top surface 154 offirst projection portion 150 to a bottom mouth 172 at bottom surface 156of first projection portion 150. Outside face 166 bounds the passage162, while inside face 168 communicates with chamber 110. Chamber 110can encircle passage 162. Passage 162 is generally circular when viewedfrom above. That is, passage 162 has a generally circular crosssectional shape at any point between the top and bottom mouths 170 and172. Other shapes can alternatively be formed.

As shown in the depicted embodiment, passage 162 is formed in firstprojection portion 150 so as to include a constricting portion 180between top and bottom mouths 170 and 172. Constricting portion 180generally corresponds to the narrowest portion of passage 162. In thedepicted embodiment, passage 162 is shaped in the form of an hourglass,with an upper portion 176 and a lower portion 178 respectively disposedabove and below constricting portion 180. During use, constrictingportion 180 prevents a portion of elongated coupler 104 (FIG. 1) frompassing all the way through passage 162, while allowing another portionof coupler 104 to extend down through passage 162 and project belowbottom surface 156 of first projection portion 150, as described in moredetail below.

Constricting portion 180 can be integrally formed with sidewall 164, asin the depicted embodiment, or can comprise a constriction insert thatis attached to or embedded within sidewall 164. Furthermore, althoughconstricting portion 180 is depicted as being generally centrallylocated between top and bottom mouths 170 and 172 of passage 162, it isappreciated that constricting portion 180 alternatively can bepositioned anywhere along passage 162. That is, constricting portion 180can be positioned adjacent mouth 170 or mouth 172, or anywhere inbetween. In addition, constricting portion 180 can completely encirclepassage 162, or can only be positioned on one side of the passage. Otherconfigurations are also possible.

Returning to FIG. 2, a pair of engagers 192 project downward from bottomsurface 156 of first projection portion 150. Engagers 192 are formed onbottom surface 156 or can be molded or attached thereto. Each engager192 is substantially similar in size and shape. The engagers 192 can besubstantially rounded, such as substantially semi-spherical as in thedepicted embodiment, or can be rectangular or form some other shape. Theengagers 192 are positioned on bottom surface 156 so as to bediametrically opposed to each other, with the bottom mouth 172 ofpassage 162 being positioned substantially half way between the engagers192.

As shown in FIGS. 1 and 2, second projection portion 152 comprises a topsurface 200 and an opposing bottom surface 202 with a perimeter sidewall204 extending therebetween. In the depicted embodiment bottom surface202 of second projection 152 lies in the same plane as floor 114 ofcentral body portion 112 so as to be horizontally displaced when barrier102 is positioned on a level surface. Alternatively, bottom surface 202can lie in a different plane than floor 114. Top surface 200 projectslongitudinally outward from second end face 132 on second end 120 and issubstantially parallel to bottom surface 202 and thus also horizontallydisposed in the embodiment depicted when barrier 102 is positioned on alevel surface.

Perimeter sidewall 204 is substantially vertical as it extends betweentop surface 200 and bottom surface 202, although this is not required.Second projection portion 152 is rounded on a distal end such that theend of second projection portion 152 is substantially semi-circular whenviewed from a position perpendicular to top surface 200 of secondprojection portion 152. In one embodiment one end of sidewall 204attaches to central body portion 112 and lies in the same vertical planeas side wall 122 and the other end attaches to central body portion 112and lies in the same vertical plane as side wall 124.

As shown in the depicted embodiment, side wall 204 has a recessedportion 206 disposed therein. Outwardly projecting from side wall 204within recessed portion 206 is a tubular stem 208. Stem 208 bounds anoutlet port 210 that extends through barrier 102 so as to communicatewith chamber 110. By virtue of its position near floor 114, outlet port210 can be used to selectively drain ballast from barrier 102.

A cap or plug 212 can be screwed into or onto or otherwise attached tostem 208 so as to seal outlet port 210 closed. In alternativeembodiments, outlet port 210 can be positioned at other locations onbarrier 102. For example, outlet port 210 can alternatively bepositioned on side wall 122 or 124 of central body portion 112 nearfloor 114. Likewise, as with inlet port 140, outlet port 210 can beformed without stem 208. It is noted that by positioning outlet port 210in a recessed portion 206, a partially protected space is provided forstem 208 and related cap or plug 212.

Extending completely through second projection portion 152 between topsurface 200 and bottom surface 202 is a passage 220. Passage 220 isgenerally centrally located on second projection portion 152. Passage220 is configured to generally align with passage 162 formed in firstprojection portion 150 of a separate identical barrier when firstprojection portion 150 is positioned so as to overlap second projectionportion 152, as discussed below.

Returning to FIG. 3, passage 220 is formed by an internal sidewall 222having an outside face 224 and an opposing inside face 226. The outsideand inside faces 224 and 226 extend from a top mouth 228 at top surface200 of second projection portion 152 to a bottom mouth 230 at bottomsurface 202 of second projection portion 152. Outside face 224 boundsthe passage 220, while inside face 226 communicates with chamber 110.Similar to passage 162 in first projection portion 150, chamber 110 canencircle passage 220.

Also similar to passage 162, passage 220 is formed so as to include aconstricting portion 238 between top and bottom mouths 228 and 230.Similar to constriction portion 180 with respect to passage 162,constricting portion 238 generally corresponds to the narrowest portionof passage 220 with an upper portion 234 and a lower portion 236 ofpassage 220 respectively disposed above and below constricting portion238. In the depicted embodiment, unlike passage 162 of first projectionportion 150, passage 220 does not have a generally circular crosssectional shape and is not symmetrical.

Upper portion 234 of passage 220 is bounded by an outside face 240 thatcomprises the portion of outside face 224 positioned above constrictingportion 238. Lower portion 236 of passage 220 is bounded by an outsideface 242 that comprises the portion of outside face 224 positioned belowconstricting portion 238.

As shown in the depicted embodiment, a portion of upper portion 234 anda portion of lower portion 236 are connected together such as by beingintegrally molded together at constricting portion 238. Constrictingportion 238 can be encircled by chamber 110. A hole 248 is formedthrough constricting portion 238, thereby allowing the passage 220 toextend from mouth 228 at top surface 200 to mouth 230 at bottom surface202. As discussed below, a portion of elongated coupler 104 (FIG. 1) canbe extended down through passage 220 and project below constrictingportion 238 of second projection portion 152.

As shown in FIG. 3, upper portion 234 of passage 220 overhangs lowerportion 236 so as to form a ledge 250 at constricting portion 238. Ledge250 faces downward towards the bottom surface 202 of second projectionportion 152 and extends between hole 248 and outside face 242. Ledge 250has an inner edge 252 which bounds hole 248. Turning to FIGS. 4 and 5,ledge 250 encircles hole 248 and has an irregular shape. As best shownin FIG. 5, inner edge 252 of ledge 250 is shaped such that hole 248 thatis formed thereby has a substantially round central section 254. Hole248 also has a pair of smaller semicircular ear-like sections 256extending away from central section 254 in diametrically opposingdirections. In the depicted embodiment, extended sections 256 extend inopposite directions that are substantially orthogonal to thelongitudinal axis 116, although this is not required.

As shown in FIG. 5, a pair of recesses 258 are formed in upper portion236 of passage 220 that extend up to and are bounded by ledge 250. Therecesses 258 are positioned so as to be diametrically opposed to eachother about central section 254 of hole 248. Ledge 250 includes a pairof diametrically opposed portions 260 aligned with recesses 258 andoffset around hole 248 by approximately 90 degrees from ear-likesections 256. Portions 260 of ledge 250 are shaped to be substantiallythe same size as central section 254 of hole 248.

Constricting portion 238 and the accompanying structure located thereatcan be integrally formed with sidewall 164, as in the depictedembodiment, or can comprise an insert that is attached to or embeddedwithin sidewall 222. Furthermore, although constricting portion 238 isdepicted as being generally centrally located between top and bottommouths 228 and 230 of passage 220, it is appreciated that constrictingportion 238 alternatively can be positioned anywhere along passage 220.That is, constricting portion 238 can be positioned adjacent mouth 228or adjacent mouth 230, or anywhere in between. Other configurations arealso possible.

As shown in FIG. 3, first and second projection portions 150 and 152 areconfigured so that the bottom surface 156 of first projection portion150 is disposed either in substantially the same plane as top surface200 of second projection portion 152 or is disposed above top surface200 of second projection 152. The term “above” is defined as being afurther distance away from floor 114.

Turning to FIGS. 6 and 7, because bottom surface 156 of first projectionportion 150 is either in the same plane as or above top surface 200 ofsecond projection portion 152, the first projection portion 150 of onebarrier 102A can overlap the second projection portion 152 of anotheridentical barrier 102B while floor 114 of central body portion 112 ofboth barriers are resting on a common support surface. When theidentical barriers 102A and 102B overlap as in FIGS. 6 and 7, passage162 of first projection portion 150 of barrier 102A generally alignswith passage 220 of second projection portion 152 of barrier 102B.

Although passage 220 is shown as extending all the way through secondprojection portion 152, that is not required. For example, in someembodiments, bottom surface 202 extends over the entire secondprojection portion 152, covering bottom mouth 230 of passage 220. Inthose cases, passage 220 would need to extend into second projectionportion 152 from top surface 200 past connecting joint 238 so thatcoupler 104 can be secured therein.

Returning to FIG. 1, one or more pockets 216 are also formed on the topsurface 200 of second projection portion 152. The pockets 216 areconfigured to receive engagers 192 disposed on the first projection 150of an identical barrier. As such, each pocket 216 is sized and shaped tosnugly receive a separate engager 192. The embodiment depicted includeseight pockets 216. In other embodiments the number of pockets can be sixor ten or any other number. As shown in FIG. 4, the plurality of pockets216 are disposed in a substantially circular pattern around top mouth228, the circular pattern having a diameter that is substantially equalto the distance between engagers 192 (FIG. 2). Each pocket 216 has amatching pocket 216 diametrically opposed to it on the opposite side ofthe circle (for example, pockets 216A and 216B). This allows each pairof pockets 216 to be able to receive the pair of engagers 192. Forexample, as shown in FIG. 6, the pair of engagers 192A and 192B ofbarrier 102A can respectively be received in the pair of pockets 216Aand 216B of barrier 102B when first projection portion 150 of barrier102A overlaps second projection portion 152 of barrier 102B.

Returning to FIG. 4, there are four pairs of diametrically opposedpockets 216 formed in top surface 200 of second projection portion 152in the embodiment depicted. This allows angles of multiples of 45degrees to be able to be formed between the two engaged barriers 102Aand 102B when engaged, as shown in FIGS. 8-10. To receive the pair ofengagers 192 in a different pair of pockets 216, first projectionportion 150 of first barrier 102A is lifted off second projectionportion 152 of second barrier 102B until no engagers 192 are received inany pockets 216. First barrier 102A is then rotated with respect tosecond barrier 102B until the engagers 192 on first projection portion150 of barrier 102A become vertically aligned with another pair ofpockets 216 on second projection portion 152 of barrier 102B. Firstprojection portion 150 of barrier 102A is then lowered onto secondprojection portion 152 of barrier 102B, causing the different pair ofpockets 216 to receive the pair of engagers 192.

Turning to FIG. 11, a single annular channel 218 can be used instead ofa plurality of individual pockets 216 to receive engagers 192. In thisregard a single engager 192 can also be used. Annular channel 218 isformed in top surface 200 of second projection portion 152. Channel 218forms a continuous ring recessed on top surface 200 and has a diametersubstantially equal to the distance between engagers 192. Thecross-sectional shape of channel 218 substantially mirrors the shape ofengagers 192 so that channel 218 can receive the pair of engagers 192 ora single engager 192.

Because annular channel 218 is a continuous channel, engagers 192 can bereceived by channel 218 at any location around channel 218, thusallowing a continuum of angles to be formed between the engagedbarriers. In the depicted embodiment, the range of angles that can beformed between two engaged barriers is about +90° to about −90°.Rotating barrier 102A with respect to barrier 102B is easier than whenusing individual pockets 216, depicted above. To receive the pair ofengagers 192 in a different location within channel 218, firstprojection portion 150 of first barrier 102A is only slightly lifted,and then rotated with respect to second barrier 102B until the desiredangle is obtained. First projection portion 150 of barrier 102A is thenlowered onto second projection portion 152 of barrier 102B, causing thepair of engagers 192 to be received in a different location withinchannel 218.

In view of the foregoing, projection portions 150 and 152 and theengagers 192 and pockets 216 are formed so that a selective angle α canbe formed between the longitudinal axis 116 of each of the coupledbarriers 102. Some of these angles are shown in FIGS. 8-10. For example,in FIG. 9 angle α is shown at +45 degrees and can also extend to −45degrees. In FIG. 10, the angle α is shown a +90 degrees and can alsoextend to −90 degrees. Here it is appreciated that by increasing thenumber of pockets 216, barriers 102 can be set at a larger number ofpredefined angles. Likewise, by using annular channel 218, barriers 102can be set at any defined angle. In addition, by moving end faces 130and 132 back, angle α can be made larger than 90 degrees. For examples,barriers 102 can be formed to extend over an angle of at least +120degrees to −120 degrees.

Although engagers 192 have been disclosed as being disposed on bottomsurface 156 of first projection portion 150 and pockets 216 have beendisclosed as being disposed on top surface 200 of second projectionportion 152, it is appreciated that in alternate embodiments, engagers192 and pockets 216 can be disposed on the opposite surface. In otherwords, engagers 192 can alternatively be disposed on top surface 200 ofsecond projection portion 152 and pockets 216 can alternatively bedisposed on bottom surface 156 of first projection portion 150. Also,although the preceding discussion discloses a pair of engagers 192 beingreceived by different pairs of pockets 216 within a plurality ofpockets, it is appreciated that the present invention can also beaccomplished by having only a single pair of pockets 216. The presentinvention can also be accomplished using only a single engager 192 thatis received within a single pocket 216, including a single engager 192received within one of a plurality of pockets 216 or by three or moreengagers 192.

Barrier 102 is typically made of a resiliently deformable polymericmaterial having strong, semi-rigid, and energy absorbing properties.Such materials include linear or cross-linked plastics that will deformunder pressure but will not fail in a brittle manner. Examples ofconventional polymeric materials include polyethylene (including HighDensity Polyethelene (HDPE)), polyvinylchloride, nylon, polycarbonate,and polypropylene. Additives such as dyes, pigments, and reinforcements,such as fibers, can also be added to the material. Florescent dies canbe added to help barriers 102 glow at night for better direction oftraffic. In one embodiment, it is preferred that barrier 102 be madefrom a recyclable plastic such as polyethylene or HDPE. This enables oldor broken barriers to be ground down and recycled into new barriers.

Barrier 102 is typically made by blow molding. Of course, other moldingprocesses, such as rotational molding, injection molding or die molding,can also be used.

In the depicted embodiment, an opening 266 is formed on the secondprojection portion 152, as shown in FIG. 1, to allow air to be blowninto the barrier during the molding process to force the plasticmaterial to fill the edges of the mold as the barrier is being formed. Afitting can be formed within sidewall 122 or 124 of second projectionportion 152 to aid in this process. Opening 266 can be closed by a plug.Independent of the method used, it is generally desirable that the wallsof barrier 102 have a substantially uniform thickness T, as shown inFIG. 3, so as to minimize shrink deformation. In one embodiment, barrier102 has a thickness T in a range between about 0.2 cm to about 1.5 cmwith about 0.3 cm to about 0.8 being more common. The thickness ischosen to optimize desired deflection and required strength properties.Other dimensions can also be used.

As noted above and shown in FIGS. 1 and 2, barrier assembly 100 alsocomprises coupler 104. Turning to FIG. 12A, coupler 104 is in the formof a pin comprising an enlarged head 268 with an elongated shaft 270extending therefrom along a longitudinal axis 272. Coupler 104 isconfigured to be inserted into passage 162 of first projection portion150 and secured therein until used to secure the barrier to anotherbarrier, as discussed below.

As shown in FIG. 12A, head 268 includes a gripping section 274 thatextends longitudinally between a first end 276 and a spaced apart secondend 278. Gripping section 274 is designed to be easily grasped andturned by a user so as to rotate coupler 104 about the longitudinal axis272. Turning to FIG. 12B in conjunction with FIG. 12A, gripping section274 is substantially plate-like, having a first side surface 280 and anopposing second side surface 282 that are substantially parallel tolongitudinal axis 272 and to each other, with a perimeter side wall 284extending therebetween. As shown in FIG. 12A, a hole 286 is formed ingripping section 274 that extends transversally completely therethroughbetween the first and second side surfaces 280 and 282, although this isnot required

As shown in FIGS. 12A and 12B, head 268 further comprises a securingsection 292 extending longitudinally away from second end 278 ofgripping section 274 to a spaced apart distal end 296. Securing section292 has a top face 298 comprised of two sections 300 and 302 thatrespectively extend transversally out from the first and second sidesurfaces 280 and 282 at second end 278 of gripping section 274 to anouter edge 304. The two sections 300 and 302 of top face 298 are shapedso as to cause top face 298 to be substantially circular in shape. Asshown in FIG. 12A, an encircling sidewall 306 extends from the outeredge 304 of top face 298 to distal end 296. Sidewall 306 issubstantially frustoconically shaped so that its diameter getsprogressively smaller as securing section 292 extends from top face 298to distal end 296. The diameter of sidewall 306 at outer edge 304 issubstantially greater than the diameter of passage 162 of firstprojection portion 150 at constricting portion 180 (FIG. 3). Because ofthis, securing section 292 cannot pass completely through passage 162,but instead sidewall 306 thereof butts up against outside face 166 ofsidewall 164 above constricting portion 180 when coupler 104 is insertedthrough top mouth 170 and into passage 162 (see FIG. 7).

Shaft 270 extends longitudinally away from distal end 296 of securingsection 292. Shaft 270 has an encircling sidewall 308 having an exteriorsurface 310 that extends from a first end 312 attached to sidewall 306,to an opposing second end 314 along central longitudinal axis 272. Shaft270 is substantially cylindrical with a substantially constant diameteras it extends between first and second ends 312 and 314, with a taperingat second end 314, if desired. Other configurations can also be used.Shaft 270 is sized so as to be able to pass through passage 162 of firstprojection portion 150 and through passage 220 of second projectionportion 152. As such, shaft 270 has a cross sectional diameter that isless than or equal to the diameter of passage 162 at constrictingportion 180 and center section 254 of hole 248 of constricting portion238, as shown in FIGS. 6 and 7.

As noted above, coupler 104 is designed to be retained within passage162 after coupler 104 has been inserted therein. Thus, coupler 104 alsoincludes means for securing coupler 104 within passage 162 of firstprojection portion 150. In the embodiment depicted in FIG. 12A, themeans for securing comprises a pair of lobes 320, radially projectingout from sidewall 308 at or near second end 314. Lobes 320 arepositioned on shaft 270 so as to be diametrically opposed to each otherrelative to central longitudinal axis 272. The distance between theoutermost portions 322 of lobes 320 is slightly greater than thediameter of passage 162 at constricting portion 180 of first projectionportion 150. As a result, coupler 104 can be retained within passage 162after being inserted therein. Thus, lobes 320 can also be consideredsecuring members of the coupler or pin 104.

Lobes 320 can be generally semicircular in shape, such as in thedepicted embodiment, or some other shape. Lobes 320 can be integrallymolded with sidewall 308, as in the depicted embodiment (see, e.g., FIG.6) or can be attached or embedded within sidewall 308. Lobes 320 can becomprised of metal, hard plastic, or other rigid material. Although twolobes are depicted, one or three or more lobes can alternatively beused. When three or more lobes 320 are used, the mating structure ofconstricting portion 238 of passage 220 would be modified accordingly toreceive the lobes.

In one embodiment, coupler 104 is inserted into passage 162 of barrier102 while barrier 102 is still warm after being blow molded. Thepliability of internal sidewall 164 while still warm allows lobes 320 topass through passage 162. Barrier 102 is then allowed to cool andharden, whereupon the hardened internal sidewall 164 then prevents lobes320 from passing back through passage 162. As such, coupler 104 isretained and secured within passage 162. Once secured within passage162, coupler 104 is able to be freely rotated about longitudinal axis272 by a user manipulating gripping section 274. In some embodiments,coupler 104 is also molded and inserted into passage 162 while coupler104 is warm. In some embodiments, coupler 104 is molded inside the samemold as barrier 102 from the same piece of material, as shown in FIG.13.

In light of the above, an exemplary method of manufacturing a barrierassembly according to the present invention can include: forming abarrier inside a mold using a polymeric material; removing the formedbarrier from the mold while the barrier is still warm; and inserting anelongated pin into a passage formed between top and bottom surfaces ofthe formed barrier before the barrier has cooled, a securing member ofthe pin being passed through a restrictive portion of the passage as thepin is inserted, the restrictive portion of the passage allowing thesecuring member to pass therethrough while the formed barrier is stillwarm, but preventing the securing member from passing therethrough whenthe barrier has cooled, thereby securing the pin within the passagewhile still allowing the pin to freely rotate within the passage.

Coupler 104 is also used to secure one barrier to another barrier. Assuch, coupler 104 also includes means for removably securing coupler 104within passage 220 of a second barrier 102. In some embodiments, themeans for securing the coupler within the passage of first projectionportion 150 also acts as the means for removably securing the couplerwithin passage 220. For example, as shown in FIGS. 6 and 7, lobes 320are also used to secure the coupler 104 within passage 220 of secondprojection portion 152 of second barrier 102B. To facilitate this, thecross sectional shape of coupler 104 at the position of lobes 320substantially matches the shape of hole 248 formed by inner edge 252 ofledge 250 of second projection portion 152. As such, the cross sectionalshape of each lobe 320 substantially matches the shape of ear-likesections 254 of hole 248 (FIG. 5). As a result, the portion of coupler104 that includes lobes 320 can be passed through hole 248 of barrier102B when lobes 320 are vertically aligned with hole sections 254.

Once lobes 320 are passed through sections 254 of hole 248, coupler 104is then rotated about longitudinal axis 272 a quarter turn by the usermanipulating gripping section 274 to the position shown in FIGS. 6 and7. This causes lobes 320 to be received within recesses 258 of passage220 of barrier 102B, with lobes 320 biasing against portions 260 ofledge 250. As a result, lobes 320 are prevented from being removed frompassage 220 of barrier 102B by ledge 250. Barriers 102A and 102B arethus secured together by the combination of securing section 292 ofcoupler 104 biasing against outside face 166 of sidewall 164 of passage162 of barrier 102A, and lobes 320 of coupler 104 biasing against ledge250 in passage 220 of barrier 102B.

When it is desired to separate barriers 102A and 102B, coupler 104 isrotated a quarter turn about rotational axis 272 so that lobes 320 areagain vertically aligned with hole sections 254 of barrier 102B. Coupler104 is then raised so that lobes 320 pass back up through hole 248 ofbarrier 102B. First projection portion 150 of barrier 102A can then belifted off of second projection portion 152 of barrier 102B, withcoupler 104 remaining within passage 162 of barrier 102A.

Coupler 104 can be made of the same types of materials listed above withregard to barrier 102. Furthermore, similar to barrier 102, coupler 104can be made by blow molding or another molding process, such asrotational molding, injection molding or die molding. In additioncoupler 104 can be molded from the same piece of material as barrier102, as noted above. In other embodiments, coupler 104 can be comprisedof metal or other material.

The preceding discussion describes but one example of a means forsecuring a coupler within passage 162 of first projection portion 150and a means for removably securing a coupler within passage 220 of asecond barrier 102. It is appreciated that alternative arrangements canbe used for one or both of the recited means. For example, FIGS. 14-17depict various embodiments of alternative means for securing the couplerwithin passage 162 of first projection portion 150 and/or means forremovably securing the coupler within passage 220.

FIGS. 14 and 15 respectively depict alternative couplers 330 and 350that can be used with the present invention. Couplers 330 and 350 aresimilar to coupler 104, discussed above, except that in addition tolobes 320 that are used as the means for removably securing the couplerwithin passage 220, couplers 330 and 350 each also include a means forsecuring the coupler within passage 162 that is separate from the lobes320.

For example, coupler 330 depicted in FIG. 14 includes a passage 332extending transversally through shaft 270. Coupler 330 is inserted intopassage 162 of barrier 102 until passage 332 passes beyond constrictingportion 180. Once passage 332 is beyond constricting portion 180, aclevis pin 334 is inserted into passage 332. Clevis pin 334 comprises ahead 336, with a shaft 338 extending therefrom to a spaced apart distalend 340. Distal end 340 of clevis pin 334 is inserted into passage 332and shaft 338 is pushed through passage 332 until distal end 340 extendsout from the other side of passage 332. Head 336 is sized so as to belarger than passage 332, thereby preventing head 336 from passingthrough passage 332. Once clevis pin 334 has been inserted into passage332, a cotter pin 342 or the like is attached to distal end 340 of shaft338, which extends out of passage 332. Head 336 and cotter pin 342secure clevis pin 334 within passage 332. Clevis pin 334 is longer thanthe diameter of passage 162 at constricting portion 180. As such, onceattached to shaft 270, clevis pin 334 prevents coupler 330 from beingretracted out of passage 162 of barrier 102.

Instead of a passage extending transversally through shaft 270, coupler350 depicted in FIGS. 15A and 15B includes an annular channel 352 formedso as to encircle shaft 270. Coupler 350 is inserted into passage 162 ofbarrier 102 until channel 352 passes beyond constricting portion 180.Once channel 352 is disposed beyond constricting portion 180, aretaining clip 354 is inserted into channel 352. As shown in FIG. 15B,retaining clip 354 is substantially c-shaped and is sized so as to beable to clip into channel 352 and remain fastened thereto, as is knownin the art of retaining clips. Retaining clip 354 has an outer diameterlarger than the diameter of passage 162 at constricting portion 180. Assuch, once attached to shaft 270, retaining clip 354 prevents coupler350 from being retracted out of passage 162 of barrier 102.

FIG. 16 depicts an alternative embodiment of a coupler 360 in whichlobes 320 are solely used as the means for securing the coupler withinpassage 162. Coupler 360 also includes a threaded portion 362 disposedat second end 314 of shaft 270. To receive coupler 360, a matchingthreaded socket or insert 364 is molded into passage 220 of barrier 102or secured thereto. Threaded portion 362 can then be screwed into socket364. As such, threaded portion 362 is another means for removablysecuring the coupler within passage 220.

FIG. 17 depicts another coupler 370 that includes alternative means forremovably securing the coupler within passage 220. Instead of a threadedconnection, coupler 370 includes two or more bayonet prongs 372 disposedat second end 314 of shaft 270 that are received within matching bayonetchannels 374 formed in passage 220 of barrier 102. Bayonet prongs 372can also double as the means for securing the coupler within passage162, if desired.

In one embodiment of the present invention means are provided formechanically mating a pair of barrier assemblies together for transportand/or storage. Turning to FIG. 18 in conjunction with FIGS. 1 and 2, byway of example and not by limitation, projecting from top wall 126 is apair of spaced apart tenons 380 and 382. In the depicted embodiment,each tenon comprises an outwardly projecting ring 384 that terminates atan end wall 386 and encircles a cavity 388. A pair of spaced apartmortises 390 and 392 are formed on floor 114 in alignment with tenons380 and 382. Tenons 380 and 382 are configured complementary to mortises390 and 392, respectively. Each mortise 390 and 392 comprises an annularwall 392 inwardly projecting from floor 114 that terminates at arecessed end wall 396. A frustum 398 centered on end wall 396 projectsout from end wall 396, terminating at or about the same plane as floor114. The frustum 398 is sized and shaped to be able to be receivedwithin cavity 388 of the corresponding tenon 380 or 382 on top wall 126of a separate identical barrier.

As depicted in FIG. 18, by seating a second barrier 102B on top ofbarrier 102A and mating top wall 126 of barrier 102A to floor 114 ofbarrier 102B, tenons 380 and 382 of barrier 102A are received withincorresponding mortises 390 and 392, respectively, of barrier 102B. Assuch, barriers 102A and 102B are mated together. The overall matedstructure has a substantially parallelepiped configuration. As a result,the mated barriers 102A and 102B are easily stacked for transport orstorage. In alternative embodiments, tenons 380 and 382 and mortises 390and 392 can be a variety of alternative configurations and need only beconstructed so that they mate together. In some embodiments, end wall386 of tenon 380 and/or 382 is omitted so that cavity 388 communicateswith chamber 110. With cavity 388 open to chamber 110, a pole with aflag or the like mounted thereon can be inserted into chamber 110through cavity 388 so that the flag will project up from barrier 102.

In the embodiment depicted, barriers 102A and 102B are configured sothat when mated the top surface and bottom surface of the assembledbarriers are substantially flat except for tenons 380 and 382 thatreceive mortises 390 and 392. This enables groups of assembled barriersto be easily and compactly stacked on top of and adjacent to one anotherfor efficient storage and/or transport. Furthermore, as shown in FIG.18, barriers 102A and 102B can be stacked together even when coupler 104is positioned within passage 162 of first projection portion 150.

Depicted in FIGS. 19 and 20 is another alternative embodiment of abarrier 400 according to the present invention wherein like elementsbetween barriers 102 and 400 are identified by like referencecharacters. Barriers 102 and 400 are substantially similar except thatbarrier 400 contains no engagers or pockets on either projectionportions 150 or 152. The first projection portion 150 of barrier 400 canstill overlap the second projection portion 152 of an identical barrier400, but the engagement is strictly by use of coupler 104 (see FIG. 1)that extends through passages 162 and 220 of first and second projectionportions 150 and 152, as previously discussed.

In view of the foregoing, it is appreciated that various embodiments ofthe present invention have a number of unique benefits. For example,select embodiments provide an engaging means in which one end of thebarrier can overlap the end of another barrier, forming an almostcontinuous wall. By using engagers that are received within pockets, asolid connection is made between barriers that prevents unwantedmovement or rotation of one barrier relative to the other. Furthermore,use of coupler 104 prevents unwanted separation of the barriers. Byproviding tenons and mortises on the barriers, select embodiments of thecurrent invention allow for easier stacking. This saves time and moneywhen transporting or storing the barriers. Furthermore, by permanentlysecuring the coupler to the barrier, the coupler will remain with thebarrier during transport and storage. This prevents separation of thecoupler from the barrier when not in use, thereby preventing loss of thecoupler. In addition, the coupler does not need to be separatelytracked, as it always remains with the barrier; this can also greatlybenefit the user.

A number of advantages are realized when used in an airport setting. Forexample, in some embodiments a portion of the side wall is slopedupward, which allows pilots to more easily see any reflective tape orcoating on the sloped portion of the side wall, thus providing a saferairport construction environment. The low profile nature of the barriershelps to ensure that the barriers will not obstruct or damage planeswhile still providing necessary guidance. In addition, the barriers areof sufficient size so that when filled with a ballast, they will not beunintentionally moved by the propeller wash or jet blast of an aircraft.Furthermore, the coupler that is used to secure two barriers together ispermanently securing to one of the barriers. As such, even if thecoupler were to somehow become loose from connecting the two barrierstogether, the coupler would still remain secured to the originalbarrier, which would prevent the coupler from becoming dislodged andpossibly causing damage to the aircraft.

Depicted in FIG. 21 is one embodiment of a flag assembly 410 that can beused with the barriers of the present invention. The flag assembly 410comprises an elongated post 412 having an encircling side surface 414that extends from a first end 416 to an opposing second end 418. Asdepicted in FIG. 23, post 412 is tubular and has an interior surface 420that bounds a passageway 422 extending along the length thereof.Returning to FIG. 21, caps 424A and B can be mounted on opposing ends ofpost 412. As will be discussed below in greater detail, extendingthrough side surface 414 towards first end 416 is an attachment opening426. In the depicted embodiment, attachment opening is shown as beingcircular but other shapes can also be used. Formed on side surface 414towards second end 418 is a mounting opening 428. In the depictedembodiment, mounting opening 428 is showed as being an elongated slot.Again, other shapes can also be used. Post 412 typically has a lengthextending between opposing caps 424A and B in a range between about 14inches to about 40 inches with about 20 inches to about 30 inches beingmore common. Other lengths can also be used.

Flag assembly 410 also includes a flag 430. Flag 430 is typically madeof a flexible material in the form of a sheet, such as a polymeric sheetreinforced with fibers. Other materials can also be used. Flag 430 canbe any desired size, shape, or color. Flag 430 includes a body portion432 and a tubular sleeve portion 434. Sleeve portion 434 can be formedby simply folding over an edge of the flag material and stitching alongthe length thereof to form a sleeve. Stitching 436 can also be formedacross an upper end of sleeve portion 434 so as to close off the upperend and thereby form a pocket 438. During use, pocket 438 can be slidover first end 416 of post 412 so as to attach flag 430 to post 412. Afastener 440, such as a screw having an enlarged head 442, can bepunched through sleeve portion 434 and then secured into attachmentopening 426, such as by being threaded therein, so that enlarged head442 holds flag 430 onto post 412. Fastener 440 is useful in that whenthe barrier on which flag assembly 410 is mounted is located on anairport runway of taxiway, propeller wash or jet blast can try and blowflag 430 off of post 412. Fastener 440 precludes the unwanted removal offlag 430 but also enables the select removal and replacement of flag 430once flag 430 has worn or for other reasons. This configuration enablesthe reuse of post 412 with different flags 430. Post 412 is typicallymade of metal or composite so that it has sufficient strength withwithstand propeller wash or jet blast without failure. However, othermaterials can also be used.

Returning to FIG. 23, partially disposed within passageway 422 of post412 is a retainer 444. It is appreciated that retainer 444 can come in avariety of different configurations. In the depicted embodiment,retainer 444 has a substantially U- or V-shaped body 446 that includes afirst arm 448 and a second arm 450. Projecting from the end of secondarm 450 is a U-shaped catch 452. Retainer 444 is formed from aresiliently flexible material. For example, retainer 444 can be formedfrom an elongated wire or ribbon of a resiliently flexile material, suchas a metal. The material is bent into the desired shape during themanufacturing process so that when arms 448 and 450 are pressedtogether, the arms seek to resiliently move back their originally formedconfiguration. During assembly, arms 448 and 450 are resiliently pressedtogether and retainer 444 is slid into passageway 442 until catch 452resiliently expands out into mounting opening 428. In thisconfiguration, catch 452 is movable between an extended position asshown in FIG. 23 and a retracted position wherein catch 452 is pushedfrom outside of post 412 back towards passageway 422. In the retractedposition, catch 452 resiliently urges back towards the extendedposition. That is, when catch 452 is released, it springs back to itsextended position projecting out of mounting opening 428.

As depicted in FIG. 22, flag assembly 410 can be used in associationwith barrier 102. To facilitate the mounting, an inlet 454 is formed ontop wall 126 that is sized to receive second end 418 of post 412. In thedepicted embodiment, inlet 454 is formed through the end wall of tenon380. In this configuration, second end 418 of post 420 can be passeddown through inlet 454 and then subsequently received within a pocket456 formed on the interior surface of mortise 390. This configurationhelps to maintain vertical alignment of flag assembly 410. Inalternative embodiments, however, inlet 454 can be positioned at otherlocations along top wall 126 and need not be received within a pocket onfloor 414. It is also appreciated that any number of inlets 454, such as2, 3, or more, can be formed on top wall 126 so that multiple flagassemblies 410 can be mounted on barrier 102.

Turning to FIG. 23, inlet 454 is encircled by an annular lip 458. Inlet454 is configured so that as second end 418 of post 412 is advanced downthrough inlet 454, catch 452 must strike against lip 458 causing catch452 to compress into the retracted position until catch 452 passes bylip 458 at which point catch 452 resiliently expands back to theextended position. The rounded configuration of catch 452 enables theautomatic movement catch 452 into the retracted position when sufficientforce is applied to post 412. In the extended position within chamber110, catch 452 precludes post 412 from being freely pulled out of inlet454. That is, post 412 can only be removed by pull up on post 412 andexerting sufficient force to cause catch 452 to compress back into theretracted position so that catch 452 can pass through inlet 454. Thisresistance to removal caused by catch 452 prevents flag assembly 410from being blown or sucked off of barrier 102 when flag assembly 410 issubject to propeller wash, jet blast, wind or other applied forces whenthe barrier and flag assembly are located on an airport taxiway orrunway or at other locations. The unwanted separation of flag assembly410 from barrier 102 can result in potentially obscuring the visibilityof barrier 102 and can also result in flag assembly 410 becomingunwanted FOD on the runway or taxiway which could potentially be suckedinto a jet engine or can cause other problems with adjacent aircraft.

One of the unique features of flag assembly 410 is that retainer 444always remains secured to post 412 and thus there is no concern thatretainer 444 could become unwanted FOD on the airport taxiway or runway.For example, if post 412 was mounted by a separate and distinct clamp orbolt, such clamp or bolt could potentially become loose or fail to beproperly attached. As a result, the clamp or bolt could become unwantedFOD which is a potential concern for aircraft. The present design avoidsthis concern.

Depicted in FIG. 24 is a modified design of a retainer 444A whichincludes all of the elements of retainer 444. Retainer 444A, however,also includes an extension arm 458 that extends from catch 452 and arelease 460 that projects out through a second mounting opening 428A onpost 412. Release 460 is configured to be disposed outside of chamber110 when catch 452 is disposed within chamber 110. In thisconfiguration, an operator can manually depress release 460 which movescatch 452 either partially or completely into the retracted position sothat it is easier to manually remove post 412 from inlet 454.

The present invention may be embodied in other specific forms withoutdeparting from its spirit or essential characteristics. The describedembodiments are to be considered in all respects only as illustrativeand not restrictive. The scope of the invention is, therefore, indicatedby the appended claims rather than by the foregoing description. Allchanges which come within the meaning and range of equivalency of theclaims are to be embraced within their scope.

What is claimed is:
 1. A method of manufacturing a barrier assembly, themethod comprising: forming a barrier inside a mold using a polymericmaterial; removing the formed barrier from the mold while the barrier isstill warm; and inserting an elongated coupler into a passage extendingfrom a top surface to an opposing bottom surface of the formed barrierwhile the barrier is still warm, the coupler comprising a shaft and asecuring member outwardly projecting from the shaft, the passage havinga constricting portion, the warm constricting portion of the barrierpliably bending as the securing member passes therethrough; and allowingthe formed barrier to cool and harden, the hardened constricting portionof the barrier preventing the securing member of the coupler frompassing back through the constricting portion of the passage or makingit more difficult for the securing member of the coupler to pass backthrough the constricting portion of the passage relative to when thesecuring member was initially passed through the warm constrictingportion.
 2. The method as recited in claim 1, further comprising formingthe coupler inside a mold using a polymeric material.
 3. The method asrecited in claim 1, further comprising forming the coupler inside thesame mold as the barrier and concurrently with the barrier.
 4. Themethod as recited in claim 1, further comprising: forming the couplerinside the same mold as the barrier and concurrently with the barrier sothat the coupler and the barrier are secured together by polymericmaterial when the coupler and barrier are first formed; and separatingthe coupler from the barrier before inserting the coupler into thepassage.
 5. The method as recited in claim 1, wherein the securingmember comprise a thread, lobe, or bayonet prong outwardly projectingfrom the shaft.
 6. The method as recited in claim 1, further comprisingattaching a retainer to the coupler after the coupler is inserted intothe passage, the retainer being sized so that it cannot freely passthrough the constricting portion of the passage.
 7. The method asrecited in claim 6, wherein the retainer comprises a pin or retainingclip that is attached to the shaft of the retainer.
 8. The method asrecited in claim 1, wherein the step of inserting the elongated couplerinto the passage includes the shaft of the coupler having a first endand an opposing second end, an enlarged head being formed on the firstend of the shaft and the securing member being formed at the second endof the shaft.
 9. The method as recited in claim 1, wherein the barrierfurther comprises an opening formed thereon with a receiver disposedwithin the opening, the receiver being configured so that if the couplerwas received within the opening, the securing member could securelyengage with the receiver.
 10. The method as recited in claim 1, whereinthe coupler rotatable within the passage of the cooled barrier.
 11. Amethod of manufacturing a barrier assembly, the method comprising:forming a barrier and a coupler inside a mold using a polymericmaterial; removing the formed barrier and coupler from the mold whilethe barrier and coupler are still warm; and inserting the formed couplerinto a passage extending from a top surface to an opposing bottomsurface of the formed barrier while the barrier and coupler are stillwarm, the coupler comprising a shaft and a securing member outwardlyprojecting from the shaft, the passage having a constricting portion,the warm constricting portion of the barrier or warm coupler pliablybending as the securing member passes through the constricting portion;and allowing the formed barrier and coupler to cool and harden, thehardened constricting portion of the barrier and hardened connectorpreventing the securing member of the coupler from passing back throughthe constricting portion of the passage or making it more difficult forthe securing member of the coupler to pass back through the constrictingportion of the passage relative to when the securing member wasinitially passed through the warm constricting portion, the couplerbeing rotatable within the passage of the cooled barrier.
 12. The methodas recited in claim 11, wherein the step of forming comprises: formingthe coupler inside the same mold as the barrier and concurrently withthe barrier so that the coupler and the barrier are secured together bypolymeric material when the coupler and barrier are first formed; andseparating the coupler from the barrier before inserting the couplerinto the passage.